Air filter arrangement; assembly; and methods

ABSTRACT

An air filter arrangement is ( 300 ) disclosed. The air filter arrangement includes strips of media comprising corrugated sheets secured to facing sheets and forming inlet and outlet flutes secured to one another in a stack. Media pack arrangements including such stacked media with a molding arrangement to secure and seal opposite side edges of the media strips, are described. Also described are filter cartridges including such media pack ( 301 ) and air cleaners including the filter cartridges. Methods of assembly and use are also provided. Also, systems of use are described.

This application is a National Stage Application of PCT/US/2005/028002,filed Aug. 5, 2005, for which priority was claimed to Ser. No.60/599,686, filed Aug. 6, 2004, Ser. No. 60/600,081, filed Aug. 9, 2004,Ser. No. 60/602,721, filed Aug. 18, 2004 and Ser. No. 60/616,364, filedOct. 5, 2004. Each of the four provisional applications and the PCTapplication is incorporated herein by reference. A claim of priority toeach, to the extent appropriate is made.

CROSS-REFERENCE TO RELATED APPLICATION

The present provisional application includes (with some edits) thecontent of, and information added to, U.S. Provisional Application Ser.No. 60/599,686, filed Aug. 6; the complete disclosure of which isincorporated herein by reference.

The present provisional application also includes (with some edits) thecontent of, and information added to, U.S. Provisional Application Ser.No. 60/600,081, filed Aug. 9; the complete disclosure of which isincorporated herein by reference.

The present provisional application also includes (with some edits) thecontent of, and information added to, U.S. Provisional Application Ser.No. 60/602,721 filed Aug. 18; the complete disclosure of which isincorporated herein by reference.

This application is being filed on 4 Aug. 2005, as a PCT InternationalPatent application in the name of Donaldson Company, Inc., a U.S.national corporation, applicant for the designation of all countriesexcept the US, and Gregory L. Reichter, Wayne R. W. Bishop, Benny KevinNelson, Darrel Wegner, Bruce Crenshaw, Vladimir Kladnitsky, Thomas G.Miller, Donald Raymond Mork, Kevin Schrage, Richard J. Osendorf, BradleyA. Kuempel, and Thomas John Lundgren, all U.S. citizens, applicants forthe designation of the US only.

FIELD OF THE DISCLOSURE

The present disclosure relates to filter media for use in filteringgases. The disclosure particularly relates to media packs that usez-filter media which comprises a corrugated media sheet secured tofacing sheet, formed into a media pack. More specifically, thedisclosure relates to such media packs and their inclusion inserviceable filter cartridge arrangements, typically for use in aircleaners. Air cleaner arrangements, methods of assembly and use, andsystems of use are also described.

BACKGROUND

Fluid streams, such as air, can carry contaminant material therein. Inmany instances, it is desired to filter some or all of the contaminantmaterial from the fluid stream. For example, air flow streams to engines(for example combustion air) for motorized vehicles or for powergeneration equipment, gas streams to gas turbine systems and air streamsto various combustion furnaces, carry particulate contaminant thereinthat should be filtered. It is preferred for such systems, that selectedcontaminant material be removed from (or have its level reduced in) thefluid. A variety of fluid filter (air or liquid filter) arrangementshave been developed for contaminant rejection. However, continuedimprovements are sought.

SUMMARY

According to a portion of the present disclosure, features useable inpreferred filter cartridges, such as air filter cartridges are provided.The features can be used together to provide a preferred filtercartridge, however some advantageous cartridges can be constructed touse only selected ones of the features. In addition, methods ofconstruction and use are provided.

In one aspect of the present disclosure, a preferred media pack isprovided, for use in or as air filter cartridges. The media packcomprises a stacked z-filter arrangement having opposite flow faces andopposite sides. At the opposite sides, ends of stacked strips aresecured in, and sealed by, molded end pieces. Preferably the molded endpieces comprise molded polyurethane. Also, a molded in place sealarrangement is provided.

Also air cleaner arrangements which use the filter cartridge as aservice component are also described.

Various preferred features for a filter cartridge, for a described typeof application, are shown. In addition, shown and described arevariations in air cleaners, air cleaner systems and an exampleenvironment of use. Also, methods of assembly are shown and described.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary, schematic, perspective view of z-filter mediauseable in arrangements according to the present disclosure.

FIG. 2 is an enlarged schematic, cross-sectional view of a portion ofthe media depicted in FIG. 1.

FIG. 3 is a schematic view of examples of various corrugated mediadefinitions.

FIG. 4 is a schematic view of a process for manufacturing mediaaccording to the present disclosure.

FIG. 5 is a cross-sectional view of an optional end dart for mediaflutes useable in arrangements according to the present disclosure.

FIG. 6 is a schematic depiction of a step of creating a blocked, stackedz-filter media pack.

FIG. 7 is a schematic side elevational view of a filter cartridgeaccording to the present disclosure.

FIG. 8 is an end elevational view of the filter cartridge of FIG. 7.

FIG. 9 is a top plan view of the filter cartridge of FIG. 7.

FIG. 10 is a cross-sectional view taken along line A-A, FIG. 9.

FIG. 11 is a schematic perspective view of an alternate filter cartridgeaccording to the present disclosure.

FIG. 12 is a top plan view of the filter cartridge in FIG. 11.

FIG. 13 is a side cross-sectional view taken along line A-A, FIG. 12.

FIG. 14 is a cross-sectional view taken along line B-B, FIG. 12.

FIG. 15 is a schematic top plan view of a cartridge/cassette useablewith the filter cartridge of FIG. 11.

FIG. 16 is a cross-sectional view taken along line B-B, FIG. 15.

FIG. 17 is a cross-sectional view taken along line A-A, FIG. 15.

FIG. 18 is a perspective view of a cartridge/cassette.

FIG. 19 is a fragmentary, schematic, cross-sectional view of a portionof an air cleaner.

FIG. 20 is a depiction of a pick-up truck in which an air cleaner systemaccording to the present disclosure can be used.

FIG. 21 is a perspective view of an air cleaner system useable with apick-up truck.

FIG. 22 is a schematic perspective view of a portion of the enginecompartment under the hood of a pick-up truck with an air cleaner systemaccording to FIG. 21 positioned therein.

FIG. 23 is an exploded perspective view of the air cleaner system ofFIG. 21 shown during a step of filter cartridge insertion or removal.

FIG. 24 is a perspective view of an air cleaner arrangement utilizingprinciples according to the present disclosure.

FIG. 25 is a side elevational view of the air cleaner arrangement ofFIG. 24.

FIG. 26 is a top plan view of the air cleaner arrangement of FIGS. 24and 25.

FIG. 27 is a cross-sectional view taken along line 27-27, FIG. 26.

FIG. 28 is a cross-sectional view taken along line 28-28, FIG. 26.

FIG. 29 is an enlarged fragmentary view of a portion of FIG. 28.

FIG. 30 is an exploded perspective view of an air cleaner of FIG. 24.

FIG. 31 is an alternate exploded perspective view of the air cleaner ofFIG. 24.

FIG. 32 is an enlarged fragmentary view of a portion of FIG. 27.

FIG. 33 is an enlarged fragmentary view of a portion of FIG. 27.

FIG. 34 is a perspective view of a body component of the air cleaner ofFIG. 24.

FIG. 35 is a top view of the component of FIG. 34.

FIG. 36 is a cross-sectional view taken along line 36-36, FIG. 35.

FIG. 37 is an enlarged view of a portion of FIG. 36.

FIG. 38 is a cross-sectional view taken along line 38-38, FIG. 35.

FIG. 39 is an enlarged fragmentary view of a portion of FIG. 38.

FIG. 40 is a perspective view of a cover component of the air cleaner ofFIG. 24.

FIG. 41 is a top plan view of the cover component of FIG. 40.

FIG. 42 is a cross-sectional view taken along line 42-42, FIG. 41.

FIG. 43 is an enlarged fragmentary view of a portion of FIG. 42.

FIG. 44 is a cross-sectional view taken along line 44-44, FIG. 41.

FIG. 45 is a perspective view of a filter cartridge useable in the aircleaner of FIG. 24.

FIG. 46 is a top plan view of the cartridge of FIG. 45.

FIG. 47 is a cross-sectional view taken along line 47-47, FIG. 46.

FIG. 48 is a cross-sectional view taken along line 48-48, FIG. 46.

FIG. 49 is an enlarged fragmentary view of a portion of FIG. 48.

FIG. 50 is a perspective view of a different air cleaner assembly.

FIG. 51 is a top plan view of the air cleaner assembly of FIG. 50.

FIG. 52 is a cross-sectional line taken along line 52-52, FIG. 51.

FIG. 53 is a cross-sectional view taken along line 53-53, FIG. 51.

FIG. 54 is an enlarged fragmentary view of a portion of FIG. 53.

FIG. 55 is a perspective view of a filter cartridge useable in the aircleaner of FIG. 50.

FIG. 56 is a top plan view of the filter cartridge of FIG. 55.

FIG. 57 is a cross-sectional view taken along line 57-57, FIG. 56.

FIG. 58 is a cross-sectional view taken along line 58-58, FIG. 56.

FIG. 59 is a top plan view of a mold arrangement useable to form moldedside panels on a media pack, for example a media pack of the generaltype shown in FIG. 45.

FIG. 59A is a perspective view of the mold arrangement of FIG. 59.

FIG. 60 is a cross-sectional view taken along line 60-60, FIG. 59.

FIG. 61 is a cross-sectional view taken along line 61-61, FIG. 59.

FIG. 62 is a cross-sectional view depicting a media pack positioned inthe mold arrangement of FIG. 59; the view of FIG. 62 showing the mold ina view analogous to FIG. 61.

FIG. 63 is a depiction of a media pack resulting from a process stepconducted with respect to the arrangement of FIG. 62 shown inverted andplaced in a mold arrangement according to FIG. 59, for molding a second,opposite, side panel.

FIG. 64 is a side elevational view of a media pack after a step ofmanufacture according to FIG. 63; FIG. 64 being a side elevational viewdirected toward a side not covered by a side panel.

FIG. 65 is a side elevational view of the media pack, FIG. 64, directedtoward a side having a molded side panel thereon.

FIG. 66 is a schematic side elevational view of the media pack accordingto FIGS. 64 and 65 positioned in a first mold section for formation of ahousing seal ring on the media pack.

FIG. 67 is a top plan view of the arrangement of FIG. 66.

FIG. 68 is a view analogous to FIG. 66, with a second mold sectionpositioned over the first mold section, for a molding operation.

FIG. 69 is a schematic view of an alternate mold operation to that shownin FIG. 68.

FIG. 70 is a top plan view of a mold arrangement useable to form a sidepanel and seal section of a filter cartridge in general accord with thefilter cartridge FIG. 55.

FIG. 71 is a cross-sectional view taken along line 71-71, FIG. 70, inFIG. 71 the mold section being depicted with a media pack positionedtherein.

FIG. 72 is a cross-sectional view taken along line 72-72, FIG. 70; inFIG. 72, the mold section being depicted with a media pack positionedtherein.

FIG. 73 is a schematic view of a mold arrangement according to FIG. 70having a media pack resulting from the step of FIGS. 72 and 73 invertedand standing therein for a molding operation, the view of FIG. 73showing the media pack standing in the mold from the point of view ofcross-section of FIG. 71.

FIG. 74 is a perspective view of a mold component useable to form asection of the filter cartridge of FIG. 55.

FIG. 75 is a top plan view of the mold component of FIG. 74.

FIG. 76 is a cross-sectional view taken along line 76-76, FIG. 75.

FIG. 77 is a cross-sectional view taken along line 77-77, FIG. 75.

FIG. 78 is a cross-sectional view of the mold arrangement of FIG. 75shown schematically with the media pack having molded sections thereonpositioned in the mold, during a step of manufacture; the view point ofFIG. 78 being from an analogous point of view of the cross-section ofFIG. 76.

FIG. 79 is a schematic, cross-sectional view of a mold arrangementuseable as an alternative arrangement for forming a filter cartridgehaving features analogous to those shown in FIG. 55.

FIG. 80 is a top plan view of a mold bottom section of the moldarrangement of FIG. 79 with a media pack positioned therein.

Some dimensions (in mm and sometimes in inches) are provided in certaindrawings, as examples. Alternate sizes are possible.

DETAILED DESCRIPTION I. Z-Filter Media Configurations, Generally

Fluted filter media can be used to provide fluid filter constructions ina variety of manners. One well known manner is as a z-filterconstruction. The term “z-filter construction” as used herein, is meantto refer to a filter construction in which individual ones ofcorrugated, folded or otherwise formed filter flutes are used to definesets of longitudinal, typically parallel, inlet and outlet filter flutesfor fluid flow through the media; the fluid flowing along the length ofthe flutes between opposite inlet and outlet flow ends (or flow faces)of the media. Some examples of z-filter media are provided in U.S. Pat.Nos. 5,820,646; 5,772,883; 5,902,364; 5,792,247; 5,895,574; 6,210,469;6,190,432; 6,350,296; 6,179,890; 6,235,195; Des. 399,944; Des. 428,128;Des. 396,098; Des. 398,046; and, Des. 437,401; each of these fifteencited references being incorporated herein by reference.

One type of z-filter media, utilizes two specific media componentsjoined together, to form the media construction. The two components are:(1) a fluted (typically corrugated) media sheet; and, (2) a facing mediasheet. The facing media sheet is typically non-corrugated, however itcan be corrugated, for example perpendicularly to the flute direction asdescribed in U.S. provisional 60/543,804, filed Feb. 11, 2004,incorporated herein by reference.

The fluted (typically corrugated) media sheet and the facing media sheettogether, are used to define media having parallel inlet and outletflutes. In some instances, the fluted sheet and facing sheet are securedtogether and are then coiled to form a z-filter media construction. Sucharrangements are described, for example, in U.S. Pat. Nos. 6,235,195 and6,179,890, each of which is incorporated herein by reference. In certainother arrangements, some non-coiled sections of corrugated media securedto facing media, are stacked on one another, to create a filterconstruction. An example of this is described in FIG. 11 of 5,820,646,incorporated herein by reference.

The term “corrugated” used herein to refer to structure in media, ismeant to refer to a flute structure resulting from passing the mediabetween two corrugation rollers, i.e., into a nip or bite between tworollers, each of which has surface features appropriate to cause acorrugation affect in the resulting media. The term “corrugation” is notmeant to refer to flutes that are formed by techniques not involvingpassage of media into a bite between corrugation rollers. However, theterm “corrugated” is meant to apply even if the media is furthermodified or deformed after corrugation, for example by the foldingtechniques described in PCT WO 04/007054, published Jan. 22, 2004,incorporated herein by reference.

Corrugated media is a specific form of fluted media. Fluted media ismedia which has individual flutes (for example formed by corrugating orfolding) extending thereacross.

Serviceable filter element or filter cartridge configurations utilizingz-filter media are sometimes referred to as “straight through flowconfigurations” or by variants thereof. In general, in this context whatis meant is that the serviceable filter elements generally have an inletflow end (or face) and an opposite exit flow end (or face), with flowentering and exiting the filter cartridge in generally the same straightthrough direction. The term “serviceable” in this context is meant torefer to a media containing filter cartridge that is periodicallyremoved and replaced from a corresponding fluid (e.g. air) cleaner. Insome instances, each of the inlet flow end and outlet flow end will begenerally flat or planar, with the two parallel to one another. However,variations from this, for example non-planar faces, are possible.

A straight through flow configuration (especially for a coiled mediapack) is, for example, in contrast to serviceable filter cartridges suchas cylindrical pleated filter cartridges of the type shown in U.S. Pat.No. 6,039,778, incorporated herein by reference, in which the flowgenerally makes a turn inside of the cartridge and as its passes throughthe serviceable cartridge. That is, in a U.S. Pat. No. 6,039,778 filter,the flow enters the cylindrical filter cartridge through a cylindricalside, and then turns to exit through an end face (in forward-flowsystems). In a typical reverse-flow system, the flow enters theserviceable cylindrical cartridge through an end face and then turns toexit through a side of the cylindrical filter cartridge. An example ofsuch a reverse-flow system is shown in U.S. Pat. No. 5,613,992,incorporated by reference herein.

The term “z-filter media construction” and variants thereof as usedherein, without more, is meant to refer to any or all of: a web ofcorrugated or otherwise fluted media secured to (facing) media withappropriate sealing to allow for definition of inlet and outlet flutes;or, a media pack constructed or formed from such media into a threedimensional network of inlet and outlet flutes; and/or, a filtercartridge or construction including such a media pack.

In FIG. 1, an example of media 1 useable in z-filter media is shown. Themedia 1 is formed from a corrugated sheet 3 and a facing sheet 4.

In general, the corrugated sheet 3, FIG. 1 is of a type generallycharacterized herein as having a regular, curved, wave pattern of flutesor corrugations 7. The term “wave pattern” in this context, is meant torefer to a flute or corrugated pattern of alternating troughs 7 b andridges 7 a. The term “regular” in this context is meant to refer to thefact that the pairs of troughs and ridges (7 b, 7 a) alternate withgenerally the same repeating corrugation (or flute) shape and size.(Also, typically in a regular configuration each trough 7 b issubstantially an inverse of each ridge 7 a.) The term “regular” is thusmeant to indicate that the corrugation (or flute) pattern comprisestroughs and ridges with each pair (comprising an adjacent trough andridge) repeating, without substantial modification in size and shape ofthe corrugations along at least 70% of the length of the flutes. Theterm “substantial” in this context, refers to a modification resultingfrom a change in the process or form used to create the corrugated orfluted sheet, as opposed to minor variations from the fact that themedia sheet 3 is flexible. With respect to the characterization of arepeating pattern, it is not meant that in any given filterconstruction, an equal number of ridges and troughs is necessarilypresent. The media 1 could be terminated, for example, between a paircomprising a ridge and a trough, or partially along a pair comprising aridge and a trough. (For example, in FIG. 1 the media 1 depicted infragmentary has eight complete ridges 7 a and seven complete troughs 7b.) Also, the opposite flute ends (ends of the troughs and ridges) mayvary from one another. Such variations in ends are disregarded in thesedefinitions, unless specifically stated. That is, variations in the endsof flutes are intended to be covered by the above definitions.

In the context of the characterization of a “curved” wave pattern ofcorrugations, the term “curved” is meant to refer to a corrugationpattern that is not the result of a folded or creased shape provided tothe media, but rather the apex 7 a of each ridge and the bottom 7 b ofeach trough is formed along a radiused curve. A typical radius for suchz-filter media would be at least 0.25 mm and typically would be not morethan 3 mm.

An additional characteristic of the particular regular, curved, wavepattern depicted in FIG. 1, for the corrugated sheet 3, is that atapproximately a midpoint 30 between each trough and each adjacent ridge,along most of the length of the flutes 7, is located a transition regionwhere the curvature inverts. For example, viewing back side or face 3 a,FIG. 1, trough 7 b is a concave region, and ridge 7 a is a convexregion. Of course when viewed toward front side or face 3 b, trough 7 bof side 3 a forms a ridge; and, ridge 7 a of face 3 a, forms a trough.(In some instances, region 30 can be a straight segment, instead of apoint, with curvature inverting at ends of the segment 30.)

A characteristic of the particular regular, curved, wave patterncorrugated sheet 3 shown in FIG. 1, is that the individual corrugationsare generally straight. By “straight” in this context, it is meant thatthrough at least 70%, typically at least 80% of the length between edges8 and 9, the ridges 7 a and troughs 7 b do not change substantially incross-section. The term “straight” in reference to corrugation patternshown in FIG. 1, in part distinguishes the pattern from the taperedflutes of corrugated media described in FIG. 1 of WO 97/40918 and PCTPublication WO 03/47722, published Jun. 12, 2003, incorporated herein byreference. The tapered flutes of FIG. 1 of WO 97/40918, for example,would be a curved wave pattern, but not a “regular” pattern, or apattern of straight flutes, as the terms are used herein.

Referring to the present FIG. 1 and as referenced above, the media 1 hasfirst and second opposite edges 8 and 9. When the media 1 is coiled andformed into a media pack, in general edge 9 will form an inlet end forthe media pack and edge 8 an outlet end, although an oppositeorientation is possible.

Adjacent edge 8 is provided a sealant bead 10, or other sealarrangement, sealing the corrugated sheet 3 and the facing sheet 4together. Bead 10 will sometimes be referred to as a “single facer”bead, since it is a bead between the corrugated sheet 3 and facing sheet4, which forms the single facer or media strip 1. Sealant bead 10 sealsclosed individual flutes 1 adjacent edge 8, to passage of air therefrom.

Adjacent edge 9, is provided seal bead 14, or seal arrangement. Sealbead 14 generally closes flutes 15 to passage of unfiltered fluidtherein, adjacent edge 9. Bead 14 would typically be applied as stripsof the media 1 are secured to one another during stacking. Thus, bead 14will form a seal between a back side 17 of facing sheet 4, and side 18of the next adjacent corrugated sheet 3. When the media 1 is cut instrips and stacked, instead of coiled, bead 14 is sometimes referencedas a “stacking bead.” (When bead 14 is used in a coiled arrangement, notdepicted herein, it is sometimes referenced as a “winding bead.”)

Referring to FIG. 1, once the media 1 is incorporated into a media pack,for example by stacking, it can be operated as follows. First, air inthe direction of arrows 12, would enter open flutes 1 adjacent end 9.Due to the closure at end 8, by bead 10, the air would pass through themedia shown by arrows 13. It could then exit the media pack, by passagethrough open ends 15 a of the flutes 15, adjacent end 8 of the mediapack. Of course operation could be conducted with air flow in theopposite direction.

For the particular arrangement shown herein in FIG. 1, the parallelcorrugations 7 a, 7 b are generally straight completely across themedia, from edge 8 to edge 9. Straight flutes or corrugations can bedeformed or folded at selected locations, especially at ends.Modifications at flute ends for closure are generally disregarded in theabove definitions of “regular,” “curved” and “wave pattern.”

Z-filter constructions which do not utilize straight, regular curvedwave pattern corrugation shapes are known. For example in Yamada et al.U.S. Pat. No. 5,562,825 corrugation patterns which utilize somewhatsemicircular (in cross section) inlet flutes adjacent narrow V-shaped(with curved sides) exit flutes are shown (see FIGS. 1 and 3, of U.S.Pat. No. 5,562,825). In Matsumoto, et al. U.S. Pat. No. 5,049,326circular (in cross-section) or tubular flutes defined by one sheethaving half tubes attached to another sheet having half tubes, with flatregions between the resulting parallel, straight, flutes are shown, seeFIG. 2 of Matsumoto '326. In Ishii, et al. U.S. Pat. No. 4,925,561(FIG. 1) flutes folded to have a rectangular cross section are shown, inwhich the flutes taper along their lengths. In WO 97/40918 (FIG. 1),flutes or parallel corrugations which have a curved, wave patterns (fromadjacent curved convex and concave troughs) but which taper along theirlengths (and thus are not straight) are shown. Also, in WO 97/40918flutes which have curved wave patterns, but with different sized ridgesand troughs, are shown.

In general, the filter media is a relatively flexible material,typically a non-woven fibrous material (of cellulose fibers, syntheticfibers or both) often including a resin therein, sometimes treated withadditional materials. Thus, it can be conformed or configured into thevarious corrugated patterns, without unacceptable media damage. Also, itcan be readily coiled or otherwise configured for use, again withoutunacceptable media damage. Of course, it must be of a nature such thatit will maintain the required corrugated configuration, during use.

In the corrugation process, an inelastic deformation is caused to themedia. This prevents the media from returning to its original shape.However, once the tension is released the flute or corrugations willtend to spring back, recovering at least a portion of the stretch andbending that has occurred. The facing sheet is sometimes tacked to thefluted sheet, to inhibit this spring back in the corrugated sheet.

Also, typically, the media contains a resin. During the corrugationprocess, the media can be heated to above the glass transition point ofthe resin. When the resin then cools, it will help to maintain thefluted shapes.

The media of the corrugated sheet 3 facing sheet 4 or both, can beprovided with a fine fiber material on one or both sides thereof, forexample in accord with U.S. Pat. No. 6,673,136, incorporated herein byreference.

An issue with respect to z-filter constructions relates to closing ofthe individual flute ends. Although alternatives are possible, typicallya sealant or adhesive is provided, to accomplish the closure. As isapparent from the discussion above, in typical z-filter media,especially that which uses straight flutes as opposed to tapered flutes,large sealant surface areas (and volume) at both the upstream end andthe downstream end are needed. High quality seals at these locations arecritical to proper operation of the media structure that results. Thehigh sealant volume and area, creates issues with respect to this.

Attention is now directed to FIG. 2, in which a z-filter mediaconstruction 40 utilizing a regular, curved, wave pattern corrugatedsheet 43, and a non-corrugated (flat) flowing sheet 44, is depicted. Thedistance D1, between points 50 and 51, defines the extension of media 44in region 52 underneath a given corrugated flute 53. The length D2 ofthe arcuate media for the corrugated flute 53, over the same distance D1is of course larger than D1, due to the shape of the corrugated flute53. For a typical regular shaped media used in fluted filterapplications, the linear length D2 of the media 53 between points 50 and51 will often be at least 1.2 times D1. Typically, D2 would be within arange of 1.2-2.0, inclusive. One particularly convenient arrangement forair filters has a configuration in which D2 is about 1.25-1.35×D1. Suchmedia has, for example, been used commercially in Donaldson Powercore™Z-filter arrangements. Herein the ratio D2/D1 will sometimes becharacterized as the flute/flat ratio or media draw for the corrugatedmedia.

In the corrugated cardboard industry, various standard flutes have beendefined. For example the standard E flute, standard X flute, standard Bflute, standard C flute and standard A flute. FIG. 3, attached, incombination with Table A below provides definitions of these flutes.

Donaldson Company, Inc., (DCI) the assignee of the present disclosure,has used variations of the standard A and standard B flutes, in avariety of z-filter arrangements. These flutes are also defined in TableA and FIG. 3.

TABLE A (Flute definitions for FIG. 3) DCI Flute/flat = 1.52:1; TheRadii (R) are as follows: A R1000 = .0675 inch (1.715 mm); R1001 = .0581inch (1.476 mm); Flute: R1002 = .0575 inch (1.461 mm); R1003 = .0681inch (1.730 mm); DCI Flute/flat = 1.32:1; The Radii (R) are as follows:B R1004 = .0600 inch (1.524 mm); R1005 = .0520 inch (1.321 mm); Flute:R1006 = .0500 inch (1.270 mm); R1007 = .0620 inch (1.575 mm); Std.Flute/flat = 1.24:1; The Radii (R) are as follows: E R1008 = .0200 inch(.508 mm); R1009 = .0300 inch (.762 mm); Flute: R1010 = .0100 inch (.254mm); R1011 = .0400 inch (1.016 mm); Std. Flute/flat = 1.29:1; The Radii(R) are as follows: X R1012 = .0250 inch (.635 mm); R1013 = .0150 inch(.381 mm); Flute: Std. Flute/flat = 1.29:1; The Radii (R) are asfollows: B R1014 = .0410 inch (1.041 mm); R1015 = .0310 inch (.7874 mm);Flute: R1016 = .0310 inch (.7874 mm); Std. Flute/flat = 1.46:1; TheRadii (R) are as follows: C R1017 = .0720 inch (1.829 mm); R1018 = .0620inch (1.575 mm); Flute: Std. Flute/flat = 1.53:1; The Radii (R) are asfollows: A R1019 = .0720 inch (1.829 mm); R1020 = .0620 inch (1.575 mm).Flute:

Of course other, standard, flutes definitions from the corrugated boxindustry are known.

In general, standard flute configurations from the corrugated boxindustry can be used to define corrugation shapes or approximatecorrugation shapes for corrugated media. Comparisons above between theDCI A flute and DCI B flute, and the corrugation industry standard A andstandard B flutes, indicate some convenient variations.

II. Manufacture of Stacked Media Configurations Using Fluted Media,Generally

In FIG. 4, one example of a manufacturing process for making a mediastrip corresponding to strip 1, FIG. 1 is shown. In general, facingsheet 64 and the fluted (corrugated) sheet 66 having flutes 68 arebrought together to form a media web 69, with an adhesive bead locatedtherebetween at 70. The adhesive bead 70 will form a single facer bead10, FIG. 1. An optional darting process occurs at station 71 to formcenter darted section 72 located mid-web. The z-filter media or Z-mediastrip 74 can be cut or slit at 75 along the bead 70 to create two pieces76, 77 of z-filter media 74, each of which has an edge with a strip ofsealant (single facer bead) extending between the corrugating and facingsheet. Of course, if the optional darting process is used, the edge witha strip of sealant (single facer bead) would also have a set of flutesdarted at this location. The strips or pieces 76, 77 can then be cutacross, for stacking, as described below in connection with FIG. 6.

Techniques for conducting a process as characterized with respect toFIG. 4 are described in PCT WO 04/007054, published Jan. 22, 2004incorporated herein by reference.

Still in reference to FIG. 4, before the z-filter media 74 is putthrough the darting station 71 the media 74 must be formed. In theschematic shown in FIG. 4, this is done by passing a flat sheet of media92 through a pair of corrugation rollers 94, 95. In the schematic shownin FIG. 4, the flat sheet of media 92 is unrolled from a roll 96, woundaround tension rollers 98, and then passed through a nip or bite 102between the corrugation rollers 94, 95. The corrugation rollers 94, 95have teeth 104 that will give the general desired shape of thecorrugations after the flat sheet 92 passes through the nip 102. Afterpassing through the nip 102, the flat sheet 92 becomes corrugated and isreferenced at 66 as the corrugated sheet. The corrugated sheet 66 isthen secured to facing sheet 64. (The corrugation process may involveheating the media, in some instances.)

Still in reference to FIG. 4, the process also shows the facing sheet 64being routed to the darting process station 71. The facing sheet 64 isdepicted as being stored on a roll 106 and then directed to thecorrugated sheet 66 to form the Z-media 74. The corrugated sheet 66 andthe facing sheet 64 are secured together by adhesive or by other means(for example by sonic welding).

Referring to FIG. 4, an adhesive line 70 is shown used to securecorrugated sheet 66 and facing sheet 64 together, as the sealant bead.Alternatively, the sealant bead for forming the facing bead could beapplied as shown as 70 a. If the sealant is applied at 70 a, it may bedesirable to put a gap in the corrugation roller 95, and possibly inboth corrugation rollers 94, 95, to accommodate the bead 70 a.

The type of corrugation provided to the corrugated media is a matter ofchoice, and will be dictated by the corrugation or corrugation teeth ofthe corrugation rollers 94, 95. One preferred corrugation pattern willbe a regular curved wave pattern corrugation, of straight flutes, asdefined herein above. A typical regular curved wave pattern used, wouldbe one in which the distance D2, as defined above, in a corrugatedpattern is at least 1.2 times the distance D1 as defined above. In onepreferred application, typically D2=1.25−1.35×D1. In some instances thetechniques may be applied with curved wave patterns that are not“regular,” including, for example, ones that do not use straight flutes.

As described, the process shown in FIG. 4 can be used to create thecenter darted section 72. FIG. 5 shows, in cross-section, one of theflutes 68 after darting and slitting.

A fold arrangement 118 can be seen to form a darted flute 120 with fourcreases 121 a, 121 b, 121 c, 121 d. The fold arrangement 118 includes aflat first layer or portion 122 that is secured to the facing sheet 64.A second layer or portion 124 is shown pressed against the first layeror portion 122. The second layer or portion 124 is preferably formedfrom folding opposite outer ends 126, 127 of the first layer or portion122.

Still referring to FIG. 5, two of the folds or creases 121 a, 121 b willgenerally be referred to herein as “upper, inwardly directed” folds orcreases. The term “upper” in this context is meant to indicate that thecreases lie on an upper portion of the entire fold 120, when the fold120 is viewed in the orientation of FIG. 5. The term “inwardly directed”is meant to refer to the fact that the fold line or crease line of eachcrease 121 a, 121 b, is directed toward the other.

In FIG. 5, creases 121 c, 121 d, will generally be referred to herein as“lower, outwardly directed” creases. The term “lower” in this contextrefers to the fact that the creases 121 c, 121 d are not located on thetop as are creases 121 a, 121 b, in the orientation of FIG. 5. The term“outwardly directed” is meant to indicate that the fold lines of thecreases 121 c, 121 d are directed away from one another.

The terms “upper” and “lower” as used in this context are meantspecifically to refer to the fold 120, when viewed from the orientationof FIG. 5. That is, they are not meant to be otherwise indicative ofdirection when the fold 120 is oriented in an actual product for use.

Based upon these characterizations and review of FIG. 5, it can be seenthat a preferred regular fold arrangement 118 according to FIG. 5 inthis disclosure is one which includes at least two “upper, inwardlydirected, creases.” These inwardly directed creases are unique and helpprovide an overall arrangement in which the folding does not cause asignificant encroachment on adjacent flutes.

A third layer or portion 128 can also be seen pressed against the secondlayer or portion 124. The third layer or portion 128 is formed byfolding from opposite inner ends 130, 131 of the third layer 128.

Another way of viewing the fold arrangement 118 is in reference to thegeometry of alternating ridges and troughs of the corrugated sheet 66.The first layer or portion 122 is formed from an inverted ridge. Thesecond layer or portion 124 corresponds to a double peak (afterinverting the ridge) that is folded toward, and in preferredarrangements, folded against the inverted ridge.

Techniques for providing the optional dart described in connection withFIG. 5, in a preferred manner, are described in PCT WO 04/007054,incorporated herein by reference. Other techniques for media managementare described in PCT application US04/07927, filed Mar. 17, 2004,incorporated herein by reference.

Techniques described herein are well adapted for use of media packs thatresult from arrangements that, instead of being formed by coiling, areformed from a plurality of strips of single facer.

Opposite flow ends or flow faces of the media pack can be provided witha variety of different definitions. In many arrangements, the ends aregenerally flat and perpendicular to one another.

The flute seals (single facer bead, winding bead or stacking bead) canbe formed from a variety of materials. In various ones of the cited andincorporated references, hot melt or polyurethane seals are described aspossible for various applications. These are useable for applicationsdescribed herein.

In FIG. 6, schematically there is shown a step of forming a stackedz-filter media pack from strips of z-filter media. Referring to FIG. 6,strip 200 is being shown added to a stack 201 of strips 202 analogous tostrip 200. Strip 200 can be cut from either of strips 76, 77, FIG. 4. At205, FIG. 6, application of a stacking bead 206 is shown, between eachlayer corresponding to a strip 200, 202 at an opposite edge from thesingle facer bead or seal. In FIG. 6, each layer is added to a top ofthe stack. Such layers could alternatively be added to the bottom.

Also, in some alternate processing approaches sealant bead 206 can beadded to the underside (i.e., facing sheet side) of each strip, asopposed to the fluted sheet (corrugated) side of each single facerstrip.

Referring to FIG. 6, each strip 200, 202 has front and rear edges 207,208 and opposite side edges 209 a, 209 b. Inlet and outlet flutes of thecorrugated sheet/facing sheet combination comprising each strip 200, 202generally extend between the front and rear edges 207, 208, and parallelto side edges 209 a, 209 b. Sides 209 a, 209 b are sometimes referencedas tail and lead ends of the media strips 200.

Still referring to FIG. 6, in the media pack 201 being formed, oppositeflow faces are indicated at 210, 211. The selection of which one offaces 210, 211 is the inlet end face and which is the outlet end face,during filtering, is a matter of choice. In some instances the stackingbead 206 is preferably positioned adjacent the upstream or inlet face211. The flow faces 210, 211, extend between opposite side faces 220,221.

The stacked media pack 201 being formed in FIG. 6, is sometimes referredto herein as a “blocked” stacked media pack. The term “blocked” in thiscontext, is an indication that the arrangement is formed to arectangular block in which all faces are 90° relative to all adjoiningwall faces. Alternate configurations are possible, as discussed in U.S.Provisional application 60/579,754, filed Jun. 14, 2004, incorporatedherein by reference. One example of an alternate configuration, would beone in which instead of each cross-section of the stacked media packarrangement having rectangular (or right quadrilateral) cross-section,at least one of the cross-sections is a oblique parallelogramcross-section. In such a parallelogram, opposite sides are parallel toone another, but adjacent sides do not meet at a right angle, but rathermeet at a defined angle other than 90°.

Still other stacked shapes are possible, depending on how the individualsheets, in forming the stack, are positioned relative to adjacentsheets.

In some instances, the media pack 201 shown will be referenced as havinga parallelogram shape in any cross-section, meaning that any twoopposite side faces extend generally parallel to one another.

It is noted that a blocked, stacked arrangement corresponding to FIG. 6is described in the prior art of U.S. Pat. No. 5,820,646, incorporatedherein by reference. It is also noted that stacked arrangements aredescribed in U.S. Pat. Nos. 5,772,883; 5,792,247; U.S. Provisional60/457,255 filed Mar. 25, 2003; and U.S. Ser. No. 10/731,564 filed Dec.8, 2003. All four of these latter references are incorporated herein byreference. It is noted that the stacked arrangement at FIG. 6 of U.S.Ser. No. 10/731,504, is a slanted or oblique parallelogram stackedarrangement.

Of course the methods disclosed are merely examples. Useable z-filtermedia packs can be formed in alternate manners.

III. A First Filter Cartridge FIGS. 7-10

Attention is directed to FIG. 7 which discloses a filter cartridgeutilizing a media pack according to the above general description.Referring to FIG. 7, at 300 a filter cartridge is depicted comprising ablocked stacked (rectangular or right (normal) parallelogram) media pack301. To seal opposite ends of the media pack 201 are positioned sidepanels 302, 303. These panels can be made in general, in accord with thedescriptions in U.S. provisional application 60/579,754, filed Jun. 14,2004.

More specifically, and referring to FIG. 6, each single facer strip 200(comprising a section of corrugated sheet and facing sheet securedtogether) has a lead edge 209 b and a tail edge 209 a. These edgesresult from cutting a continuous strip of single facer into theindividual sheets used to form the media pack stack. The lead end andtail ends need to be sealed closed. For the arrangement of FIG. 19, thissealing is conducted by side panels 302, 303.

In preferred arrangements, as described below, panels 302, 303 will bemolded directly to the media pack, to seal the lead and tail ends of thestrips of single facer, within the media pack. By “molded directly to”in this context, it is meant that there is no preform in the side panel,rather the side panel is formed in place on and joined to the mediapack. This would distinguish, for example, a preform molded side piecewhich is attached to the media pack by a potting material.

The media pack 301 has opposite flow faces 305, 306. In use, air flowsthrough the media pack 301 from one of the flow faces 305, 306 to theother. The direction of flow is typically a matter of choice for thesystem of use. Often, the media pack 301 would be positioned with flowface 305 as the outlet flow face, but alternatives are possible.

Adjacent to, but spaced from surface 305 toward surface 306, is providedperipheral seal ring 310. The particular seal ring 310 depicted, is anaxial pinch seal ring, although alternatives are possible. Herein, sealring 310 will sometimes be referred to as a housing seal arrangement,since it is a seal member positioned in the filter cartridge 300 at alocation desirable for forming a seal with housing components, when thefilter cartridge 300 is positioned in an air cleaner for use.

The filter cartridge 300 of FIG. 7 can be made by: (a) providing themedia pack 301; and, (b) molding panels 302, 303 thereto in separatemolding operations, and then finally molding pinch (housing) sealarrangement 310 thereto, in a three shot molding process. Alternativesare possible, for example a single shot mold could be prepared and used.

If desired, a protective sheet or panel could be provided over the mediapack surface 312 and also a second protective sheet over an oppositeside or surface of the media pack 201. Such panels could be formed froma variety of materials such as cardboard, plastic sheets, etc. Suchpanels can be secured in place by being placed against the media pack301 when the panels 302, 303 are molded.

In a typical cartridge 300 as shown, cartridge 312 and an oppositesurface of the media pack 301, is at least 50%, typically at least 70%uncovered of molded material. Some molded material is positionedthereover, in association with the housing seal 310. However, portionsof the opposite molded panels 302, 303 may extend partially over thesides 312 (and opposite side). However, in general and in preferredarrangements, one pair of surfaces corresponding to surface 312 and anopposite surface, in the media pack, will be at least 50%, typically atleast 70% uncovered by molded material directly molded to the media pack301. By “directly molded to” in this context and other context herein,it is meant that the portion defined is formed in a molding operationhaving the identified portion of the media pack in the mold and with theresin at least partially bonded directly to the media pack. Thus, again,a preformed end piece which the media pack is secured by potting, is notan end piece directly molded to the media pack.

As explained, in some instances surfaces 312 (and the correspondingopposite surface) can be covered by a preformed piece such as acardboard or plastic section embedded within end pieces 302, 303 and ifdesired partially within housing seal arrangement 310, securing theprotective cover in place. Such a cover would not correspond to material“molded directly to” the media pack, in accord with the abovedefinitions.

Cartridge 300 is particularly configured with molded panels 302, 303having opposite ends 316, 317. These ends can be configured to engagehousing pieces, when pinch seal 310 is sealed between the housingpieces. When this approach to abutting regions 316, 317 is used, themedia pack is not suspended within the housing by the seal 310, ratherit is also secured in place by abutment with housing pieces at regions316, 317 to convenience. Surfaces 316, 317 can be irregular, i.e., havebumps and indents, due to mold stand-offs. This is shown at ends 316, inFIG. 9 with alternating projections 316 a and indents or recesses frommold stand-offs 316 b. (Similar indents along other edges of moldedareas can also be from mold stand-offs.)

Herein, surfaces such as surfaces 316, 317 which form abutment(non-sealing) surfaces for support with a housing, in use, willsometimes be referred to as “axial abutment surfaces,” or “compressionends” the term axial in this context referring to abutment with forcesin the direction of air flow through the media pack 301, betweensurfaces 306, 305.

As indicated above, a “axial abutment surface” or a “compression end”may sometimes be formed with a plurality of bumps and also (if desired)a plurality of recesses (or alternatively stated projections andrecesses) thereon.

A variety of materials can be utilized for the molded panels 302, 303and seal arrangement 310. Materials such as those described in U.S.Provisional application 60/579,754, filed Jun. 14, 2004, can be used. Ingeneral such materials are polyurethanes, typically foamedpolyurethanes. Although alternatives are possible polyurethanes havingan as-molded density of no greater than about 30 lbs./cu.ft. (0.48g/cc), typically no greater than about 22 lbs/cu.ft. (0.35 g/cc), andusually within the range of about 10-22 lbs./cu.ft. (0.16-0.35 g/cc),are useable. Typically materials having a hardness, Shore A, of nogreater than 30, and typically no greater than 20, often within therange of 12-20, are useable. Harder materials can be used, in someapplications.

Attention is directed now to FIG. 8, in which the cartridge 300 is shownin side view; the viewer seeing panel 302, the opposite side being amirror image. Panel 303 extends completely over the media pack 301 atthis end, sealing edges of the media pack 301 at this location.

In FIG. 10, a cross-sectional view of the cartridge 300 is depicted.Here it can be seen that the seal arrangement 310 is not adjacent tosurface 305, and includes a contoured surface 310 a with a recess ontrough 310 b, facing in the same direction as surface 305 a, and atapered region 310 c, directed toward end 306. A housing can beappropriately configured to engage seal arrangement 310, with engagementinto recess 310 b, to pinch, axially, seal arrangement 310 to provide ayield to bypass flow around the cartridge, when installed. By “axial” inthis context and related context, it is meant that forces are generallydirected in the same direction as extension between flow faces 305, 306.

In a typical molding operation, panels 302 and 303 would be formed(separately) in the same mold arrangement, with, for example in theinstance of panels 302, 303, FIG. 10, media pack sides 301 a, 301 b,respectively, directed down into the mold. Although alternatives arepossible, for example, seal arrangement 310 could be formed with eithersurface 305 or surface 306 directed down into the mold. Typically sealarrangement 310 would be formed with surface 305 directed down. As aresult, the entire seal arrangement 310 would be molded in a single sealoperation, with the plane of the mold generally corresponding to theplane in which the rectangular seal arrangement 310 sits. Alternativesare of course possible.

Although alternatives are possible, the particular seal arrangement 310depicted is recessed toward surface 306 from surface 305. In thisinstance, the recess is about 1-10 mm, although alternatives are alsopossible here. The recess of seal arrangement 310 toward surface 306from surface 305, provides for regions 316 projecting beyond the sealarrangement 310, to operate as non-sealing axial abutment surfaces withhousing members, leaving seal arrangement 310 available to be sealed atan axial pinch seal. This facilitates an arrangement in which theelement is not suspended at the seal arrangement 310, but rather isseparately secured in place in the air cleaner, during use.

It is noted that media pack 301, FIGS. 7-10, is shown with a pleatlength (distance between flow faces) of about 170-175 mm, and arectangular configuration of about 240-250 mm by about 165-175 mm.Alternate sizes can be used. In addition, an arrangement in which theprojecting portion of the gasket 10 is about 9.5 mm wide and about 12.7mm thick shown, with a tapered extension 310 to be about 25.4 mm long.Alternatives can be used.

IV. An Alternate Arrangement FIGS. 11-19

An alternate cartridge 400 is depicted in FIG. 11. The cartridge 400comprises a blocked stacked (rectangular) media pack 401 having oppositeflow faces 402, 403. The arrangement has side panels 405, 406, molded tothe media pack 401 to seal opposite side edges of the z-filter mediapack. The cartridge includes a seal gasket 408 adjacent surface 402. Thegasket 408 has four side extensions 409, 410, 411 and 412.

The cartridge 400 can be used with air flow from surface 402 towardsurface 403, or surface 403 toward surface 402. The direction is amatter of choice, depending on the air cleaner involved. In a typicalarrangement, the filter cartridge 400 will be mounted such that the airflow is from surface 403 to surface 402, as indicated in the descriptionbelow.

Side panels 405, 406 can be made similarly to the side panels 302, 303,FIG. 7. For a particular embodiment shown, cartridge 400 has beenconfigured to be optionally used in a cassette described below, whichwould then be inserted into air cleaner housing for use.

FIG. 12 is a top view of cartridge 400. FIG. 13 is a cross-sectionalview along line A-A, FIG. 13. FIG. 14 is a cross-sectional view alongline B-B, FIG. 12.

In order to prepare cartridge 400, media pack 401 can be inserted into amold arrangement to form panels 405, 406, a separate molding operationbeing used for each. This molding can be used to simultaneously formgasket sections 412, 410 respectively. Then section 409 could be formedby putting side 420, FIG. 14, in the mold; and gasket section 411 couldbe formed by putting side 421, FIG. 14, into the mold. A dovetail typeconnection (or tongue and groove) could be used at the corners of thegasket 408. Thus, cartridge 400 could be prepared in a four shot moldprocess, as opposed to a three shot mold process as used for thearrangement of cartridge 300, FIG. 10. However, a three-shot approachcould be used, as could a single shot approach.

If a four shot mold process as described above is used, the gasket 408does not result from a molding in a single plane in which therectangular gasket 408 sits. Rather, each of the four sections is moldedseparately, generally with the mold being in the same plane as a side ofthe cartridge 400 along which the section of gasket 408 extends. Thiscan be used to create different shapes and extensions in any one or moreof the gasket sections, if desired.

Cover panels (cardboard, plastic, etc.) could be put over sides 420,421, if desired, before molding.

In FIG. 11 at 430, indents from mold stand-offs are shown.

Attention is now directed to FIGS. 15-18, which show a preformed plastic(in this instance generally rectangular) cassette 500 into whichcartridge 400 could be positioned for use, for eventual installationinto a filter arrangement. Referring to FIG. 16, cassette 500 includesopen end 501 and opposite end 502 having grid 503, FIG. 15, extendingthere across. The cartridge 400 would be inserted into cassette interior505, FIG. 17, through end 501, with surface 402 positioned to align withend 501. This would rest gasket 408 against gasket sealing surface(pressure flange) 506. Edges 405 a and 406 a, FIG. 13, of cartridge 400could be configured to engage cassette grid 503, as abutment surfaces,to support the cartridge position. The side walls of the cassette 500can be provided with a slight inward taper toward end 502.

The cassette 500 is depicted in perspective, in FIG. 18.

Space between the cassette 500 and a housing wall can be used for soundattenuation. Installation would involve compressing the gasket 408between surface 506 and a portion of a housing, in use. A schematic ofone possibility is shown in FIG. 19, in which cassette 600, cartridge601, comprising media pack 602 (with flow faces 604 and 605), sealarrangement 603 and housing pieces 610, 611 are assembled to form aseal. Gap 612 allows for some sound attenuation control. In FIG. 19, thegasket 603 is surrounded by cassette housing rim 610 and cassette rim611, and is biased into sealing against surface 615 by cassette pressureflange 617 and housing pressure flange 618.

It is noted that the media pack for cartridge 400 is shown with a flutelength (distance between flow faces) of about 175 mm, and a media packouter perimeter of about 165 mm by about 239.4 mm. Alternatives can beused. It is also noted that a gasket width of about 22-29 mm is shown,although alternatives can be used; by width in this context it is meantdistance of extension outwardly from the media pack.

V. Systems of Use FIGS. 20-22

In FIG. 20, a system for use of an air cleaner according to the presentdisclosure is shown. Referring to FIG. 20, a pick-up truck 700 isdepicted, comprising wheel base 701, bed 702, driver/passenger cab 703and engine compartment 704 covered by hood 705. An air cleaner systemwould be positioned for example under the hood 705 within the enginecompartment 704. Pick-up truck 700 is meant to be a representativeexample of a variety of vehicles, and no specific make, model or year isintended.

Referring to FIG. 21, air cleaner system 710, positionable, for example,under hood 705, is depicted comprising air cleaner housing 711, downstream air plenum 712 and resonator 713.

Attention is now directed to FIG. 22 in which the interior of the enginecompartment 704 is viewable schematically. Air cleaner system 710 can beviewed as positioned where appropriate.

Attention is now directed to FIG. 23, in which the air cleaner system710 is shown in exploded view.

The air cleaner housing 711 generally comprises bottom, base or body 720and removable access cover 721. An air cleaner cartridge 725 (in thisinstance rectangular) is shown, comprising media pack 726 (in thisinstance rectangular) and gasket arrangement 727. The cartridge 726 maybe generally as described above. The particular variation shown, is withgasket 727 aligned with a flow face of the media pack 726, in thisinstance an outlet flow face. Alternate shapes can be used.

Such a cartridge 725 would typically be formed with molded side panelsat opposite sides 730, 731. At the top 732 and an opposite bottom, notshown, moldings could be used, or separate pieces such as plastic sheetsor cardboard could be placed. Alternatively, the media pack 726 could beexposed to these locations depending on the system and systemrequirements.

The air cleaner base 720 defines an interior 740. In use, the cartridge725 is slid into the interior 740, from a top 720 a or verticallocation, with gasket 727 slid into receiver 742. This would typicallybe done with the outlet air plenum 712 previously pivoted away fromsurface 743 in the direction of arrow 734. Pivoting could beaccomplished by having pins, not shown, in a lower portion 750 of outletplenum 712, which engage a portion of housing base 720. After thecartridge 725 is fully slid into position, outlet plenum 712 can bepivoted against surface 743, in an opposite direction to arrow 734, andcover 721 can be put in place with various clamps 760 or latches can beused, to ensure sufficient axial force against gasket 727 to ensureseal. The system 711 is shown closed, in this manner, in FIG. 21. Theplenum 712 can be provided with a support grid positioned to extendacross an outlet flow face of cartridge 725, if desired.

Still referring to FIG. 23, receiver 742, into which gasket 727 is slid,during operation, is a three-sided channel comprising pressure flange742 a and outer rim 742 b. The outer rim 742 b extends along an outerperiphery of the gasket 727. The pressure surface 742 a will providepressure to a side of gasket arrangement 727 which is facing towardcartridge inlet flow surface 761.

The reference to a “three-sided channel” was meant to indicate thatregion 742 shown (although alternatives are possible) generallycomprises a u-shaped channel, having two opposite side extensions andone base extension, in this instance each side extension extending at anangle of about 90° to the base extension, and each of the extensionsbeing straight.

Similarly, access cover 721 includes a three-sided channel 780 thereon,comprising a top member 780 a and opposite side members 780 b and 780 c,again forming a u-shape, in this instance an inverted u-shape, with theside extensions 780 a, 780 b, each extending a right angle to the topextensions of 780 a. Again, channel 780 comprises an outer rim 781 and apressure flange 782.

Referring to FIG. 23, tube 790 is shown positioned for deliveringfiltered air into an engine intake or similar construction.

It is noted that with an air cleaner system such as system 710, acassette such as cassette 600, FIG. 19, or cassette 500, FIG. 18, can beused around cartridge 725, to facilitate assembly.

It is noted that attached to the outlet plenum 712 is a resonator 713having a generally club shape with large end 770, narrow end 771 andelbow 772 therebetween. The resonator 713 will be referred to herein asa “club shaped resonator” secured to the outlet plenum 712 to providefor acoustic attenuation.

Still referring to FIG. 22, additional equipment to be attached to thissystem are shown including: MAFS (Mass Sensor) 794, TMAP or pressure tap795, PVC port 796 and service indicator 797.

Filter cartridges according to the present disclosure can be made in avariety of sizes. One that would be convenient for the pick-up truck 700of FIG. 20, would be a rectangular filter cartridge is about 150 mm(140-160 mm) deep, is about 254 mm (about 250-260 mm) high wheninstalled, and about 220 mm (210-230 mm) wide, when installed. Again, avariety of sizes or shapes could be used, depending on the application.

VI. Example Air Cleaners FIGS. 24-58

A. A First Example Air Cleaner, FIGS. 24-49

Reference numeral 800, FIG. 24, depicts an example air cleaner includingfeatures, and applying selected principles, according to the presentdisclosure. The air cleaner 800 comprises a housing 800 a that includesa filter cartridge receiving body or air cleaner body or base, 801 and acover or access cover 802. The cover 802 is secured to the body 801 bylatches 803, in this instance over center wire latches, althoughalternate arrangements to secure could be used.

The air cleaner 800 includes a mounting arrangement 805 thereon, formounting to a framework or other portions of a vehicle or otherequipment for use.

Service access to an interior 809, of the air cleaner 800, isaccomplished by releasing latches 803, and separating cover 802 frombody 801.

In the particular examples shown, the body 801 has a portion 801 a ofgenerally regular parallelogram shape, in this instance a square orrectangular cross-section, with an end section 810 tapering to acircular air flow aperture 811. In this instance air flow aperture 811is an outlet aperture, although in some configurations it configured asan inlet aperture.

Analogously, cover 802, has a portion of regular parallelogramcross-sectional shape, in this instance square or rectangular, at region812, where it encounters body 801. Cover 812 then tapers in region 813,to a circular air flow aperture 814. In this instance, aperture 814 isan inlet aperture, although alternatives are possible.

Although alternatives are possible, in normal use air flow would bethrough inlet 814, through an internally received filter cartridgedescribed further below, and outwardly through outlet 811.

In FIG. 25, a side elevational view of air cleaner 800 is depicted.

In FIG. 26 a top plan view of air cleaner 800 is depicted.

FIG. 27, is a cross-sectional view taken along line 27-27, FIG. 26. InFIG. 27, internally received cartridge 820, can be seen. Cartridge 820is a filter cartridge comprising a media pack 821 positioned in a flowpath of air from inlet 814 to outlet 811. The media pack 821 preferablycomprises a stacked z-filter media arrangement, as described hereinabove. The media pack 821 includes a first (in this instance inlet) flowface 824 and a second, opposite (in this instance outlet) flow face 825,with filtering flow, during use, extending therebetween.

The filter cartridge 820 is described in further detail below inconnection with other figures. Referring to FIG. 27, it can be seen thatfilter cartridge 820 includes opposite molded side panels 826, 827 alongtwo opposite sides of the media pack 821. Such panels are described, forexample, above in connection with FIGS. 5-10 at 300.

Still referring to FIG. 27, the filter cartridge 820 includes a gasketor seal member 829, pinched between seal flange 831 on the cover 802 andseal flange 832 on the body 801, to form an axial pinch seal. Sealingpressure is maintained by the clamps 803. In the embodiment shown, sealmember 825 is molded in the cartridge 820.

Attention is now directed to FIG. 28, which shows a cross-sectional viewof air cleaner 800 taken along line 28-28, FIG. 26. Here filtercartridge 820 is also viewable within interior 809. It can be seen thatthe opposite sides 836, 837 of the media pack 821 viewable in thiscross-section, do not include molded panels thereon. This is analogousto what was described hereinabove, in connection with the filtercartridge of FIGS. 8-10. Of course sides 836, 387 could be provided withmolded protective panels if desired, or protective panels such aspreformed cardboard panels or plastic panels, secured to the cartridge,as described above.

FIG. 29 is an enlarged view of a portion of FIG. 28. Seal member 829 canbe seen pinched between seal flange 831 and seal flange 832 as discussedabove. Regions 829 a, of seal member 829 would actually be distorted(compressed) during sealing, and in FIG. 29 they are shown with an outerperimeter before distortion, to facilitate an understanding of whatcompression occurs during sealing.

It is noted that seal region 829 includes a trough 829 b therein, andflange 831 includes a projection 831 a, sized to project into trough 829b, with interference to facilitate sealing and securing of the cartridge820 in place. Flange 831 includes annular projection 831 b whichsurrounds gasket 829, and bottoms out against flange 832, althoughalternatives are possible.

Attention is now directed to FIG. 30, which shows air cleaner 800 inexploded perspective view. In FIG. 30, it can be seen how cover 802 canbe removed from body 801, to allow service access to cartridge 820.

Referring to FIG. 30, molded panel 826 can be viewed. The panel 826comprises opposite edges 826 a, 826 b, each comprising alternatingrecesses 826 d and bumps or projections 826 e. This is similar to whatwas described previously in connection with cartridge 300 of FIGS. 8-10.Opposite panel 827 is similarly configured, at opposite edges 827 a and827 b.

Edges 826 a and 826 b (and 827 a, 827 b), are used to support the filtercartridge 820 in position, within the housing 800 a.

FIG. 31 is an alternate perspective view of air cleaner 800, againdepicting body 801, cover 802 and cartridge 820. Within interior 801 aof body 801 is viewable a stop arrangement 840. The stop arrangement 840is positioned to be engaged by edge 826 b of panel 826 and edge 827 b ofpanel 827, when cartridge 820 is inserted. Stop arrangement 840comprises opposite sides 841 and 842, only side 841 being viewable inFIG. 31. Sides 841 and 842 are both viewable in the cross-section ofFIG. 27.

Referring again to FIG. 31, cover 802 includes an interior 802 a, andstop arrangement 850 therein. The stop arrangement 850 comprises twostops 851, 852, only stop 851 being viewable in FIG. 31. Both stops 851and 852 are viewable in the cross-section of FIG. 27.

Stops 851, 852 are positioned, respectively, to engage edges 827 a, 826a of cartridge 820, during assembly.

As a result, the housing 800 a, is configured with cover 802 and 801sized and positioned to pinch the side molds 826, 827 axially, duringassembly. This will support the media pack weight between the stoparrangements 840, 850, so that the weight of the media pack is notsuspended by the gasket arrangement 829, during use.

In FIG. 32, engagement between stop 852 and molding edge 826 a is shown.In FIG. 33 engagement between stop 842 and mold edge 826 b is shown. Theopposite side involving molding 827 would be a mirror image of FIGS. 32and 33.

Referring to FIG. 31, it is noted that there is no grid shown extendingacross interior 801 a, at a bottom end or lower end surface 825 ofcartridge 820, when assembled. Also, there is no grid across cover 802.A grid or other med pack support construction could be positioned ateither end, if desired.

In FIG. 34, housing body member or base 801 is depicted, without certainother portions of the assembly thereon. In FIG. 35, body 801 is depictedin top view. In FIG. 36, a cross-sectional view taken along line 36-36,FIG. 35 is viewed. In FIG. 37, an enlarged fragmentary view of a portionof FIG. 36 is viewable. In FIG. 37 mount 860 is shown for a latch memberto be mounted on a side wall 861 of body 801. Further, flange 832, whichprovides a seal surface for engagement with gasket 829, FIG. 29, isshown.

FIG. 38 depicts body 801 in cross-sectional view taken along line 38-38,FIG. 35. FIG. 39 is an enlarged fragmentary view of a portion of FIG.38, showing another mounting piece 865 for a latch, as well as a portionof flange 832 and a sealing surface therewith.

Referring to FIG. 36, stop or support arrangement 840 comprising stopmembers 841, 842 are readily viewable.

Although alternatives are possible, for the particular arrangementshown, body 801 is a sheet metal or formed metal body, and stops 841,842 are bars or tubes welded therein. Of course molded arrangementscould be used, in some applications.

In FIG. 40 a perspective view of a cover member 802 is depicted. In FIG.41, a top plan view is shown. In FIG. 42 a cross-sectional view takenalong line 42-42, FIG. 41 is shown. In FIG. 42 stop arrangement 850 isdepicted comprising stops 851, 852. Although alternatives are possible,cover 802 depicted is made from sheet metal or formed metal components,with stops 851, 852 comprising bars or tubes welded in position. Ofcourse alternative arrangements, such as plastic arrangements, can beused.

FIG. 43 is an enlarged fragmentary view of a portion of FIG. 42. Inparticular in FIG. 43 portions of stop 852 and flange 831 are viewable.Example dimensions are shown for these components, to provide anexample. The dimensions in brackets are in millimeters, with otherdimensions shown in inches, sometimes in parens.

FIG. 44 is a cross-sectional view taken along line 44-44, FIG. 41. Sidewall 802 b of cover 802 can be viewed, with flange 831 thereon.

In FIGS. 45-49, filter cartridge 820 is depicted. FIG. 45 is aperspective view. FIG. 46 is a top plan view. FIG. 47 is across-sectional view taken along line 47-47, FIG. 46. FIG. 48 is across-sectional view taken along line 48-48, FIG. 46. FIG. 49 is anenlarged fragmentary view of a portion of FIG. 48. In FIGS. 45-49,dimensions are provided, to indicate an example arrangement useable inan air cleaner according to FIGS. 24-44.

Referring to FIG. 49, it is noted that trough 895 is provided alongmedia pack 821, surrounding the media pack 821. Trough 895 is anartifact from a preferred molding arrangement used to construct gasket829. The flange 831, FIG. 44, would not typically be configured toproject deep into region 895.

Filter cartridge 820 may be generally as described above with respect tocartridge 300, FIGS. 8-10.

Referring to FIG. 45, filter cartridge 820 comprises media pack 821having opposite molded panels 826, 827 and a molded housing sealarrangement 829. The molded housing seal arrangement 829 has fourextensions 829 a, 829 b, 829 c and 829 d, to completely surround themedia pack 821. The media pack defines opposite flow surfaces 824, 825and opposite sides 836, 837, which are either uncovered, partiallyuncovered, or in some examples could be covered by a sheet material suchas plastic or cardboard secured within the molded panels 826, 287 toextend therebetween.

It is noted that the particular assembly of FIGS. 24-49 is shown withoutthe utilization of a separate cassette to receive the filter cartridge820. Of course an alternative arrangement could be constructed, whichutilizes such a cassette.

B. A Second Air Cleaner Assembly, FIGS. 50-58

Reference numeral 900, FIG. 50, depicts second air cleaner arrangement,comprising a housing 900 a. The housing 900 a includes a body or base901 and an access cover 902. Although alternatives are possible, base901 has a parallelogram shaped portion 901 a, in this instance having asquare or rectangular cross-section, tapering to a circular air flow end911, in this instance an outlet. Similarly access cover 902 includes amatching parallelogram section 902 a, in this instance square orrectangular, and tapering to a circular air flow passage 914, in thisinstance an air flow inlet. Cover 902 can be secured to base 901 bylatches, not shown, analogously to those shown in FIG. 24.

General external features of air cleaner 900 are similar to air cleaner800, FIG. 24, and thus less detailed description is presented regardingthem.

In FIG. 51 a top plan view of air cleaner 900 is shown. In FIG. 52 across-sectional view taken along line 52-52, FIG. 51 is shown. In FIG.52 cartridge 920 comprising a stacked z-filter media pack 921 is shown.The cartridge 920 depicted has opposite molded-on side panels 923, 924and a gasket arrangement 929. Although alternatives are possible, inthis instance gasket arrangement 929 is molded-on at a location flushwith flow face 925 of media pack 921.

The media pack includes opposite flow faces 925, 926; for thearrangement shown face 925 being an inlet face and face 926 being anoutlet face, although alternatives are possible.

FIG. 53 is a cross-sectional view taken along line 53-53, FIG. 51. Heremedia pack 921 of cartridge 920 is depicted, with opposite side 930, 931that do not include moldings thereon. Of course moldings could be put atthis location, as well as protective panels such as preform panels ofcardboard or plastic. However these are not required in someapplications.

In FIG. 54, an enlarged fragmentary cross-sectional view of a portion ofFIG. 53 is shown. Gasket 929 is seen as being pinched between flange 940on cover 902 and flange 941 on body 901. In FIG. 54 perimeter shape ofgasket 929 is shown distorted, to show where the distortion or pinchingwould occur. It is noted that flange 940 also includes thereon anannular extension 940 a positioned to surround the gasket 929, duringassembly. When assembled, extension 940 a could be sized to bottom outagainst flange 941, during clamping.

In FIG. 54, an edge or projection of cover 902 is shown projecting intogasket 929 to facilitate sealing. Also an edge or projection of body 901is shown projecting into gasket 929 to facilitate sealing. Theprojecting edge of body 901 that projects into the gasket 929 isradially offset from the edge of cover 902 that projects into gasket929; the projecting edge of body 901 being radially offset toward mediapack 929. That is, the edge of body 901 on the downstream or body side,which projects into the gasket 929, is closer to the media pack 922,than the edge on the upstream or cover side 902 that projects intogasket 929, for the example shown.

In FIG. 54, some dimensions are shown, to indicate a workable example.The dimensions in brackets are in millimeters, the other dimensions arein inches.

FIGS. 55-58, a filter cartridge 920 useable in air cleaner 900 isdepicted. Filter cartridge 920 is analogous to filter cartridge 400,FIGS. 11-14. FIG. 55 is a perspective view, FIG. 56 a top plan view,FIG. 57 a cross-sectional view taken along line 57-57, FIG. 56; and,FIG. 58 a cross-sectional view taken along line 58-58, FIG. 56. In FIGS.56-58, example dimensions are shown in inches (and in brackets inmillimeters) to provide an understanding of a working example. Of coursealternatives can be used.

Referring to FIG. 55, filter cartridge 920 comprises media pack 921having: opposite molded side panels 923, 924; opposite flow surfaces925, 926; and molded housing seal arrangement 929 thereon, comprisingfour sections 929 a, 929 b, 929 c and 929 d.

The cartridge 920 further defines opposite surfaces 930, 931 asexplained above, that do not include moldings thereon. These surfacesextend between molded panels 923, 024. Of course surfaces 930, 931 couldbe partially covered by molded arrangements, if desired. Further theycan be covered or partially covered by protective covering such ascardboard sheets, plastic sheets, etc., if desired.

It is also noted that for the air cleaner assembly of FIGS. 50-58, thearrangement is shown without any support grid extending across the aircleaner, to support flow surface 926 or flow surface 925, in use. One ormore such grids could be provided, if desired.

Further, it is noted that in FIGS. 50-58, no cassette arrangement isshown separately supporting the media pack within the air cleaner. Sucha cassette arrangement could be used, if desired.

Finally, referring to the cross-section of FIG. 52, no stop arrangementis shown for supporting the media pack 921. A stop arrangement could beutilized in some applications, if desired.

VII. Example Methods of Cartridge Manufacture

General methods of manufacture of filter cartridges as described herein,are mentioned above. In this section example manufacturing processes andmold arrangements are described.

A. An Example Approach to Manufacture of a Filter Cartridge According toFIGS. 7-10 and 45.

As indicated above, the filter cartridge 820 of FIG. 45 can be viewed ascomprising three molded sections, namely: panel 826, opposite panel 827and housing seal ring 829. (The filter cartridge 300 of FIGS. 7-10 issimilar.)

One useable approach to manufacturing the filter cartridge of FIG. 45,is to use a three step mold procedure, molding each of these componentsseparately. Such a procedure is illustrated in FIGS. 59-68.

Referring first to FIG. 59, a mold arrangement 1000 is depicted, useablefor molding panels generally corresponding to panels 826, 827, FIG. 45.It is noted that the mold 1000 depicted in FIG. 59, is configured formolding panels with a slight modification from panels 826, 827. Forexample, mold 1000 is not configured to form the projections andrecessions observed along edges 826 a, 826 b, 827 a and 827 b, FIG. 45.However, phantom lines 1001 in FIG. 59 indicate how the mold could bemodified, for forming these features.

Also, mold 1000 utilizes a different media pack stand-off arrangement,than one which would have been used to create panels 826, 827, each witha trough (corresponding to trough 826 f, FIG. 45), being the artifactfrom molding. This will be further understood from the discussions belowof a molding process using FIG. 59.

In FIG. 59A, mold arrangement 1000 is shown in perspective view.

Referring to FIG. 59, in general mold arrangement 1000 comprises a moldcavity 1002, with a media pack stand-off projection arrangement 1003positioned therein. A variety of configurations can be used for thestand-off projection arrangement 1003. The particular configurationshown in FIG. 59, uses four (4) projections 1005. In an alternative, acontinuous rib could be used, which would result in a trough similar tothat shown at 826 f at FIG. 45.

In FIGS. 60 and 61, cross-sectional views of mold 1000 are depicted.

In a typical molding operation, a resin would be poured into the moldcavity 1002, and then a media pack would be set into the cavity formolding. Alternatively in some arrangements the media pack could befirst positioned, and then the mold filled with the appropriate resin.

Typically a resin will be used, as characterized above, which is afoaming resin (such as a foamed polyurethane) that will increase involume during molding. However, a wide variety of resin materials can beused.

In FIG. 62, mold 1000 is depicted with the media pack 1007 positionedtherein, for a molding operation. From FIG. 62, one can see the mediapack 1007 which stands above the bottom 1002 a of cavity 1002, uponstand-off projection arrangement 1003.

After the molding operation of FIG. 62, the resulting media pack 1007with one side panel 1008 thereon, would be inverted and reset in themold for molding the opposite side panel. This process is shown in FIG.63.

In FIGS. 64 and 65, media pack 1012 resulting from a media pack 1007having two opposite molded side panels 1008, 1009 thereon, from amolding operation described thus far, is shown. In FIG. 65, the viewpoint is toward side panel 1008. In FIG. 64 the media pack 1007 isviewed toward a side which extends between the molded side panels 1008,1009. Referring to FIG. 65, in the final construction, air flow throughthe media pack 1007 will be generally between flow face 1010 and anopposite flow face 1011. In FIG. 65, opposite sides 1013 and 1014 arenoted. These would typically not have a molded panel thereon, althoughthey could be formed that way. They also could be left mostly uncoveredor be provided with a preformed covering, for example cardboard orplastic.

The arrangement 1012 of FIG. 64, 65, will preferably have added to it,for formation of a filter cartridge, a housing seal arrangement. Withrespect to this, attention is directed to FIG. 66-68.

Referring to FIG. 66, a mold section piece 1020 is shown schematically,with arrangement 1012 positioned therein, for formation of a housingseal. FIG. 67 is a top plan view of the arrangement of FIG. 66. In FIG.66, arrangement 1012 is positioned with a flow surface 1010 directed up,and opposite flow surface 1011 directed down.

Still referring to FIG. 66, mold section 1020 has three cavity sectionstherein as indicated at 1020 a, 1020 b and 1020 c. 1020 c is a sectionin which resin will typically not be located, and is positioned forengagement by one of the flow surfaces 1011 (or alternatively 1010) ofthe arrangement 1012. Mold cavity section 1020 a, will form a portion ofa housing seal arrangement, as described below, from resin therein.Section 102 b is a transition section, which provides for receipt of oneof the side panels 1009, 1008.

In FIG. 68, the arrangement of FIG. 66 is shown with a second mold piece1021 positioned over first mold piece 1020, to fully define mold cavity1023.

In operation, after (or if desired, before) the media pack arrangement1012 is positioned within mold piece 1020, resin would be positioned incavity section 1020 a. Mold piece 1021 would then be positioned inplace, and the resin would rise to fill the cavity 1023, during cure, tomold a resulting housing seal member directly to media pack arrangement1012. Alternatively, resin could be added through a mold fill, forexample at 1023 a. The cavity 1023 can be shaped to form a variety ofhousing seal arrangements, based on preferred selection. The particularcavity 1023 of FIG. 68 is configured to form housing seal generallyanalogous to seal 829. FIG. 45. Thus, cavity 1023 surrounds the mediapack 1007, and the assembly 1012.

As described previously, the filter cartridge of FIG. 45 is configuredwith the seal arrangement 829 recessed away from surface 824. Indeedreferring to FIG. 68, mold section 1020 is depicted with central recess1020 c therein, allowing the filter media pack arrangement 1012 to bepushed sufficiently down within the mold piece 1020, so that flowsurface 1011 (of the media pack) will project past cavity section 1020a.

Of course the mold piece 1020 could be configured to provide analternate location (relative to end face 1011, FIG. 68) of the resultingmolded housing seal arrangement. An example is provided in FIG. 69 whichshows a construction analogous to FIG. 68, except without the media packand with the mold sections separated. Mold section 1028 which generallycorresponds to mold piece 1020, is shown without a central recess butwith cavity 1029. Thus as a media pack (not shown) and a second moldpiece 1030 are positioned for molding, it can be seen that the resultinghousing seal arrangement, formed in cavity 1029 will not be recessedfrom the corresponding end surface of the media pack.

It is noted that in the various molding operations described inconnection with FIGS. 66-69, for formation of a housing seal, in eachinstance the mold cavity would be configured to provide contact, beingthe resulting seal and either: another molding molded to the media pack;or, directly to the media pack, completely around the media pack, so asto ensure no leakage between the housing seal arrangement and the mediapack, when the filter cartridge resulting from the mold operation isused in an air cleaner. Even if a preform is positioned underneath aportion of the housing seal arrangement along some sides, the moldconfiguration should be such that at least a portion of the moldedhousing seal arrangement directly contact the media pack completelyacross that surface, to ensure an appropriate leak-free seal. As tosides with a sealing mold already in place, the housing seal needs to beselected from material that will sufficiently join with the already inplace mold (such as side panels 1008, 1009) to ensure no leakagetherebetween. The types of polyurethane materials characterizedhereinabove are appropriate and adequate for these purposes.

From the above descriptions, it will be understood that a variety ofalternatives are possible, from selection of cavity configurations, forforming a filter cartridge of the general type characterized in FIG. 45and discussed above. The process characterized in connection with FIGS.59-64, is generally referred to herein as a “three shot mold process,”since three molding steps, with three separate applications of resin,are used. Herein below in connection with the remaining figures,alternate mold approaches are described.

B. An Example Approach for Formation of a Filter Cartridge According toFIGS. 11-14 and 55.

The filter cartridge 920 of FIG. 55 generally comprises a media pack 921having two opposite side panels 923, 924 and a peripheral sealarrangement 929. (In FIGS. 11-14 a similar filter cartridge is shown.)Such an arrangement could be made with the three-shot mold processpreviously described with mold piece modified to accommodate themoldings shown. An alternate example approach to formation of such afilter cartridge is described herein, in connection with FIGS. 70-78.

In FIG. 70, a top plan view of a mold arrangement 1050 useable forformation of panels 923, 924, FIG. 55 is shown. The mold arrangement1050 is also configured to form sections of housing seal arrangement929; i.e., sections 929 a, 929 c, FIG. 55.

Referring to FIG. 70, mold arrangement 1050 defines mold cavity 1051.

In FIG. 71 generally corresponds to a cross-sectional view of mold piece1050, taken along line 71-71, FIG. 70. FIG. 72 corresponds to moldarrangement 1050 viewed from the cross-sectional view of line 72-72,FIG. 70. In FIGS. 71 and 72, a media pack 1052 is shown positioned inmold 1050.

From FIGS. 70-72, it will be understood that mold arrangement 1050defines cavity 1051 and media pack stand-off projection arrangement1053. A variety of configurations of projection arrangements can beused. The particular projection arrangement 1053 depicted, comprises asegmented line of projections 1056 and a continuous projection 1057. Thedirection of extension of continuous projection 1057 corresponding to aline parallel to a segmented line defined by projections 1056.

Cavity 1051, FIGS. 70, 71, further defines a housing seal segmentforming trough 1059.

In FIGS. 71 and 72, mold arrangement 1050 is schematically depicted withthe media pack 1052 therein, for formation of a side panel and housingseal arrangement section. In a typical operation, the liquid resin to becured to form a side panel and housing seal section will be positionedwithin the mold cavity 1051, before the media pack 1052 is put intoposition. The resin would then cure, typically with an increase involume from foaming, resulting in a panel and a section of housing seal.

The opposite panel will be formed by removing resulting combination1060, FIG. 73 from the first molding step, inverting it, and replacingit in the mold (after positioning additional resin in the mold).

Referring to FIG. 70, it is noted that trough section 1059 is configuredat ends 1061 to form opposite ends of the housing seal arrangement, witha recessed center therein. This will facilitate knitting of side stripsin the housing seal arrangement, during the next steps of molding,described below in connection with FIGS. 74-78.

Referring first to FIG. 55, the partially completed cartridge after FIG.73, i.e., after the molding steps described thus far, would be a mediapack 921, having side panels 923, 924 thereon, with housing sealsections 929 a and 929 c of housing seal arrangement 929. Sections 929 band 929 d of housing seal arrangement 929 are yet to be formed.

Attention is now directed to FIG. 74, in which a mold arrangement 1070useable to form housing seal sections 929 b and 929 d, FIG. 55, isshown. In FIG. 74 mold arrangement 1070 is shown in perspective view. InFIG. 75 mold arrangement 1070 is shown in top plan view. FIG. 76 is across-sectional view taken along line 76-76, FIG. 75. In FIGS. 75 and 76mold cavity 1072 is viewable. FIG. 77 is a cross-sectional view of moldarrangement 1070, taken along line 77-77 thereof.

In FIG. 78, mold arrangement 1070 is shown with a media pack (shownschematically) positioned therein. In typical use, resin will be placedin mold cavity section 1072, before the media pack is positioned in themold. Upon cure, typically with foaming and thus increase in volume, theresin in mold cavity section 1072 will form one of the strips 929 b, 929d, FIG. 55, in the resulting product. Of course the resulting partiallycompleted cartridge could then be removed from the mold, inverted andplaced in the mold with additional resin, to form the remaining one ofthe strips 929 b, 929 d.

The mold cavity is configured to provide the knitting of the resin inthe joints 1075, FIG. 55, in the molding process.

The process described with respect to FIGS. 70-78, is a four-shot moldprocess. That is, four resin additions to mold arrangements are used.Alternate mold processes are possible, for example a three-shot processas described above in connection with FIGS. 59-69, except modified forthe appropriate mold cavity, could be used.

In the next section an alternate one-shot mold process is described.

C. An Example Approach for Formation of a Filter Cartridge Using aOne-Shot Mold Process, FIGS. 79-80.

The reference numeral 1080, FIG. 79, indicates a mold assembly useableto form a filter cartridge comprising a z-filter media pack having: (a)two opposite molded side panels; and, (b) a molded housing seal ring, ina one-shot mold process. Referring to FIG. 79, the mold arrangement1080, shown schematically, is a two-piece mold having a mold base 1082,defining a mold cavity 1083; and, a mold cover 1085.

Still referring to FIG. 79, positioned within the mold cavity 1083 is az-filter media pack 1087.

In FIG. 79, the mold arrangement 1080 with a media pack 1087 therein, isdepicted in cross-section, to facilitate an understanding of theconcept. The media pack 1087 is positioned such that the opposite moldedside panels will be formed at opposite sides 1090, 1091, by resin inportions 1093, 1094 of the cavity 1083. Portions 1093 and 1094 wouldextend along sides 1090, 1091 respectively, but would not extend, in atypical preferred application, completely across ends of the media pack1087 extending between the sides 1090, 1091.

For orientation, for the particular arrangement depicted, the flowsurfaces of the media pack 1087 will be positioned at 1096 and 1097.

Of course in filter cartridge arrangements analogous to those describedin FIGS. 45 and 55, the housing seal arrangement comprises a ring in aplane extending circumferentially around the media pack. This type ofhousing seal arrangement can be formed in the same resin shot as thepanel sections at 1093, 1094, with the mold arrangement according tomold arrangement 1080. In particular, shelf 1100, and mold volume abovethat shelf defined by outer mold surface 1101, define cavity portion1102, of cavity 1083, in which the housing seal ring will be formed.Shelf 1100 and outer surface 1101 would be configured in the moldarrangement 1080, to completely surround the media pack 1087, as shownin FIG. 80. (In FIG. 80, a top plan view of the arrangement of FIG. 79is shown, with cover 1085 removed.)

Several modes of operation are possible. In one, after the media pack1087 is positioned in the mold cavity 1083, resin would be poured intocavity portions 1093, 1094 and 1102, in a single resin pour. Cover 1085could then be put in place, and the resin allowed to rise and cure. Inan alternate mode of operation, the mold cover 1085 could be positionedbefore the resin is inserted, the resin could be inserted through amold-fill opening and mold cover 1085, as shown at FIG. 79 at 1105 (withventing shown at 1106).

Of course still further possibilities can be used. However, the examplesindicate how a filter cartridge having two opposite molded side panelsand a molded circumferential housing seal arrangement could be made in asingle mold pour, with techniques according to the disclosure.

Of course the shape or contour of shelf 1100 and outer surface 1101, canbe modified as desired, to provide selected or preferred housing sealshapes or contours.

In a typical application, the cavity 1083 would be provided withappropriate structure therein for centering the media pack 1087 andinhibiting flash from extending across surfaces of the media pack 1087,any undesired amount.

If desired, with any of the mold approaches described herein above inconnection with FIGS. 59-80, extra pieces can be positioned against themedia pack on surfaces as desired. Such pieces comprising cardboard,plastic or other sheet material, can simply be positioned on the mediapack before an insertion into the molds, or the mold arrangements can bemodified to accommodate the pieces being separately added.

D. Variations to Form Filter Cartridges with Molding CompletelyPeripherally Around the Media Pack, Leaving Only the Opposite Flow FacesExposed.

Herein above, in general the filter cartridges described or shown eachhave a pair of opposite molded panels, molded directly to the mediapacks to seal ends of the single facer strips used to make the mediapacks. Thus, the resulting filter cartridge only has side panels moldedto two opposite sides of the media pack, since only two sides of themedia pack have exposed lead and tail ends of the single facer stripsused to form the media pack. In the alternative, filter cartridges canbe formed which have moldings extending completely peripherally aroundthe media packs; i.e., covering four sides. These could be made with aone-shot process as described in connection with FIGS. 79 and 80, byextending the portion (1094) of the mold cavity (1083) that forms theside panels to run completely around the media pack (as the portion(1102) that forms the seal trough already extends completelyperipherally around the media pack). Variations of the four-shot moldprocess could also be used to make such an arrangement, by having themold of FIG. 78, which only forms a section of the housing seal,modified to form a complete panel with a housing seal section thereon.

An approach analogous to that described in connection with FIGS. 59-68could also be used. However instead of the process being a three-shotmold process, it would be a five-shot mold process, since four shotswould be required to first form the four panels, before the housing sealis molded.

E. Variations in Housing Seal Position.

The various examples provided herein, the housing seal generally sits ina plane parallel to a plane of the inlet face and the outlet face orboth, sometimes in the same plane as the inlet face and the outlet face.Alternatives are possible, using the various techniques describedherein, but modifying the molds appropriately.

F. Modifications from Blocked Media Packs.

The examples provided each use a blocked media pack, in which outsidesurfaces intersect at a right angle. Alternatives are possible,including ones, for example, in which the media pack has been formedfrom layers in a stack that are off-set sufficiently, to generate amedia pack having at least one cross-section which comprises an obliqueparallelogram; i.e., a parallelogram in which while opposite sides areparallel, the sides do not intersect at a 90° angle. An example of sucha media pack is known in U.S. Provisional Application 60/579,754, filedJun. 14, 2004 (at FIG. 6A), the complete disclosure of which isincorporated herein by reference. A similarly shaped media pack could beused in molding operations as described herein, for generation of afilter cartridge.

VIII. A General Characterization of the Filter Cartridges and Methods

In general terms, filter cartridges of the types described hereincomprise a filter media pack comprising a stacked construction of singlefacer strips, each single facer strip typically comprising a flutedsheet secured to a facing sheet in position to define inlet and outletflow channels extending between first and second opposite flow faces.The filter cartridge further includes a molded side panel arrangementcomprising at least first and second opposite molded panels moldeddirectly to, and in sealing coverage over, a first set of two oppositesides (or ends) to the media pack defined by lead ends and tail ends ofthe strips of media. The filter cartridge further includes a housingseal arrangement molded into the filter cartridge arrangement. Thehousing seal arrangement can be: (a) molded onto the molded side panelarrangement; (b) molded directly onto the media pack; or, (c) it canhave portions molded to both. Typical arrangements described herein,have portions either: (a) molded to both; or, (b) arranged such thatportions are integral with the molded side panels while other portionsare molded directly to the media pack.

Within the filter cartridge including molded side panel arrangements,the molded side panel arrangements can be configured to extend partiallyacross sides which are otherwise partially not covered. Typically, thereis at least 50% (by area) exposed media (i.e., media not covered bymolding) positioned on these uncovered sides. In some instances thesesides can be covered by preform side wall sections, for examplecardboard or plastic sheets.

The housing seal arrangement in some instances is an integrally moldedportion of the molded side panel arrangement. By “integrally moldedportion” in this context, it is meant that the housing seal arrangementis molded from the same resin pool and at the same time, as the moldedside panel arrangement. An example of this is described above, inconnection with the one-shot molding process. Also, portions (orsections) of the housing seal arrangements are integrally molded withthe molded side panel arrangement in the four-shot molded approachdescribed above.

Of course, in some applications the housing seal arrangement is not anintegrally molded portion of the molded side panel arrangement. Forexample, the housing seal arrangement can be molded to the media packafter the molded side panel arrangement has already been formed. Anexample of this was described above in connection with the three-shotmold approach.

In some examples, the media pack is a blocked, stacked construction.However the media pack, as described, can be a slanted stackedconstruction defining at least one oblique parallelogram cross section.The term “slanted, stacked construction” in this context, refers to amedia pack that is stacked, but stacked such that two opposite parallelsides do not extend perpendicular to the sides they intersect.

In some arrangements the housing seal arrangement comprises a singleintegrally molded perimeter seal extension. Examples of this weredescribed above in connection with the one-shot mold process descriptionand the three-shot mold process description.

In other examples, the housing seal arrangement comprise a plurality ofseparately molded sections or extensions. An example of this wasdescribed above in connection with the four-shot molded processapproach.

In some preferred filter cartridges, the molded side panel arrangementcomprises two opposite mold panels each having or defining a firstcompression edge (or housing engagement edge) adjacent the first flowface and the second compression edge adjacent the second flow face and,the housing seal arrangement comprises a housing seal perimeterextension that is recessed from alignment with each compression edge (orhousing engagement edge). An example of this was illustrated herein inconnection with the cartridge of FIG. 45. The edges, which formcompression edges, can also be characterized as “housing engagementedges,” “axial abutment surface;” or by similar terms. Preferred edges,which comprise a non-planar contour, typically a projection/recesscontour, are shown in FIG. 45. In this example, each compression edgecomprises a plurality of (at least two) projections at least one andtypically in a plurality of recesses, although alternateprojections/recess arrangements are possible.

Housing seal arrangements described hereinabove in connection with theexamples of FIGS. 45 and 55, are axial pinch seals, that is each isconfigured to be pinched axially between housing components, when thefilter cartridge is installed in use. The term “axial” and “axially” inthis context, refers to a direction of seal force generally parallel tothe direction of air flow through the media pack, as opposed to towardor away from a center line of the media pack extending between the flowfaces.

The housing seal arrangement (and the side moldings) can be providedfrom a variety of materials. When separately molded, it is not requiredthat they all be the same. An example material useable for both the sealand the side moldings described herein is polyurethane. An examplepolyurethane characterized is a foamed polyurethane which will increasein volume during use. Preferred ones increase by at least 40% in volume,to fill the mold cavities (typically at least 80% in volume) and havingan as-molded density of no greater than 30 lbs/cu.ft (0.48 g/cc),typically no greater than 22 lbs/cu.ft. (0.35 g/cc) and usually with inthe range of 10 lbs/cu.ft (0.16 g/cc) to 22 lbs/cu.ft (0.35 g/cc); and,a hardness (Shore A) typically of not greater than 30, preferably notgreater than 25 and typically within the range of 12 to 22. Of coursepolyurethanes outside of this range can be used, but the characterizedones are advantageous for manufacturing and handling.

Also described herein are air cleaner arrangements comprising a housinghaving an inlet section and an outlet section, and a filter cartridgetypically as characterized herein, positioned therein. An example aircleaner in which an outlet section is selectively rotatably pivotablerelative to the inlet section to release sealing pressure in the housingseal arrangement is described hereinabove, in connection with FIG. 23.This arrangement can be further characterized as having an access cover,with a housing body section forming a three-sided receiver for the sealand media pack, of the filter cartridge.

An air cleaner arrangement in which the housing further includes aremovable cassette therein, the cassette being configured to receive thefilter cartridge therein during use, as shown.

Methods (processes) of forming a filter cartridge arrangement aredescribed, which generally involve molding a molded side panelarrangement and a housing seal arrangement to a filter media pack. Theterm “molding . . . to” in this context and variants thereof, is torefer to a process in which the molding is generated on a portion of thefilter media pack, as opposed to preformed and then attached to themedia pack for example by potting. A one-shot mold process, a three-shotmold process and a four-shot mold process are described, as examples.

1. A filter cartridge arrangement comprising: (a) a filter media packcomprising a stacked construction of individual strips of media eachcomprising a fluted sheet secured to facing sheet to define inlet andoutlet flow channels extending between first and second, opposite, flowsurfaces; (b) a molded side panel arrangement comprising at least firstand second, opposite, molded panels molded directly to, and in sealingcoverage over, a first set of two opposite sides of the media packdefined by lead ends and tail ends of the strips of media; and, (c) ahousing seal arrangement molded in place on the filter cartridgearrangement; (d) the filter media pack having a second set of twoopposites sides each of which is at least partially not covered by themolded side panel arrangement.
 2. A filter cartridge arrangementaccording to claim 1 wherein: (a) the filter media pack second set oftwo opposite sides is such that each is at least 50% not covered bymolded the side panel arrangement.
 3. A filter cartridge arrangementaccording to claim 2 wherein: (a) each media pack side of the second setof two opposite sides is covered by a pre-form sidewall section.
 4. Afilter cartridge arrangement according to claim 1 wherein: (a) thehousing seal arrangement is an integrally molded portion of the moldedside panel arrangement.
 5. A filter cartridge arrangement according toclaim 1 wherein: (a) the housing seal arrangement is not an integrallymolded portion of the molded side panel arrangement.
 6. A filtercartridge arrangement according to claim 1 wherein: (a) the media packis a blocked, stacked, construction.
 7. A filter cartridge according toclaim 1 wherein: (a) the media pack is a slanted, stacked, constructiondefining at least one oblique parallelogram cross-section.
 8. A filtercartridge arrangement according to claim 1 wherein: (a) the housing sealarrangement comprises a single, integrally molded, perimeter sealextension.
 9. A filter cartridge according to claim 1 wherein: (a) thehousing seal arrangement comprises a plurality of separately molded sealsections.
 10. A filter cartridge arrangement according to claim 1wherein: (a) the molded side panel arrangement comprises two, opposite,molded panels each defining a first edge adjacent the first flow faceand a second edge adjacent the second flow face; and, (b) the housingseal arrangement comprises a housing seal perimeter extension recessedfrom alignment with each edge.
 11. A filter cartridge arrangementaccording to claim 10 wherein: (a) the first and second edges of thetwo, opposite, molded panels define a projection/recess contour.
 12. Afilter cartridge arrangement according to claim 11 wherein: (a) thefirst and second edges each comprise a plurality of projections.
 13. Afilter cartridge arrangement according to claim 1 wherein: (a) thehousing seal arrangement is an axial pinch seal; and, (b) the housingseal arrangement and the molded side panel arrangement each comprisepolyurethane.
 14. A filter cartridge arrangement according to claim 1wherein: (a) the housing seal arrangement and the molded side panelarrangement each comprise foamed polyurethane having an as-moldeddensity of no greater than 30 lbs/cu.ft.
 15. An air cleaner comprising:(a) a housing having an inlet section and an outer section; and, (b) afilter cartridge arrangement comprising: (i) a filter media packcomprising a stacked construction of individual strips of media eachcomprising a fluted sheet secured to facing sheet to define inlet andoutlet flow channels extending between first and second, opposite, flowsurfaces; (ii) a molded side panel arrangement comprising at least firstand second, opposite, molded panels molded directly to, and in sealingcoverage over, a first set of two opposite sides of the media packdefined by lead ends and tail ends of the strips of media; and, (iii) ahousing seal arrangement molded-in-place on the filter cartridgearrangement; (iv) the filter media pack having a second set of twoopposite sides each of which is at least partially not covered by themolded side panel arrangement.
 16. An air cleaner according to claim 15wherein: (a) the outlet section is selectively rotationally pivotablerelative to the inlet section to release sealing pressure on the housingseal arrangement.
 17. An air cleaner according to claim 15 wherein: (a)the filter cartridge is removably positioned within a preformedcassette; and, (b) the filter cartridge and cassette are positionedwithin the housing with the housing seal member pinched between a flangeon the cassette and a portion of the housing.
 18. A filter cartridgearrangement comprising: (a) a filter media pack comprising a stackedconstruction of individual strips of media each comprising a flutedsheet secured to facing sheet to define inlet and outlet flow channelsextending between first and second, opposite, flow surfaces; (b) amolded side panel arrangement comprising at least first and second,opposite, molded panels molded directly to, and in sealing coverageover, a first set of two opposite sides of the media pack defined bylead ends and tail ends of the strips of media; (i) the molded sidepanel arrangement comprising two, opposite, molded panels each defininga first edge adjacent the first flow face and a second edge adjacent thesecond flow face; and, (ii) the first and second edges of the two,opposite, molded panels defining a projection/recess contour; and, (c) ahousing seal arrangement molded in place on the filter cartridgearrangement; (i) the housing seal arrangement comprising a housing sealperimeter extension recessed from alignment with each edge.